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Axle so rusted need opinions on best approach

Discussion in '1st Gen. Tacomas (1995-2004)' started by renots, Sep 13, 2025 at 4:33 PM.

  1. Sep 13, 2025 at 8:55 PM
    #21
    renots

    renots [OP] 15mpgTaco just entered the chat

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    Doug
    Southern Illinois
    Vehicle:
    04 Tacoma SR5 TRD OR 3.4L M/T 4x4
    OME suspension lift 882 coil overs Aftermarket UCAs and upper ball joints with zerks Arb bumper with warn winch All new dakkar leaf springs Diff drop kit Suspension parts purchased at wheelers off road 32” all terrains and nicer bullet hole rims.
    Was watching heliacoil demo while you dug that info up. I have a tap and dye set. I’ll go to harbor freight and see about extracting the bolts I broke in the morning. Surely they make a knock off of the craftsman set

    I have a torch but not map gas just propane
     
  2. Sep 13, 2025 at 9:23 PM
    #22
    renots

    renots [OP] 15mpgTaco just entered the chat

    Joined:
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    Member:
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    Messages:
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    Gender:
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    Doug
    Southern Illinois
    Vehicle:
    04 Tacoma SR5 TRD OR 3.4L M/T 4x4
    OME suspension lift 882 coil overs Aftermarket UCAs and upper ball joints with zerks Arb bumper with warn winch All new dakkar leaf springs Diff drop kit Suspension parts purchased at wheelers off road 32” all terrains and nicer bullet hole rims.
    One of the four bolts I snapped was related to lspv to clarify, three were shallow bolts holding on little folding fasteners that secure a brake line to the axle
     
  3. Sep 14, 2025 at 12:10 PM
    #23
    renots

    renots [OP] 15mpgTaco just entered the chat

    Joined:
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    Member:
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    Messages:
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    Gender:
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    First Name:
    Doug
    Southern Illinois
    Vehicle:
    04 Tacoma SR5 TRD OR 3.4L M/T 4x4
    OME suspension lift 882 coil overs Aftermarket UCAs and upper ball joints with zerks Arb bumper with warn winch All new dakkar leaf springs Diff drop kit Suspension parts purchased at wheelers off road 32” all terrains and nicer bullet hole rims.
    So, I couldn’t extract the broken bolts, drilled out the holes and tied with twine, added new line clips. I was able to crack loose the nuts holding the fuel filter bracket surprisingly, I would like to replace the whole rusted bracket. Tried to locate those bolts under the carpet in the cab but couldn’t locate. Adding pics of rust as promised. Rear passenger side bolt for the bed missing, and if anyone knows if it’s possible to change the bolts out for the fuel filter bracket, let me know how. They might just be studs attached to the underside of the cab body, I’m not sure but if they are actual bolts they must be under that hard resin liner that is under the carpet. I took seat out and everything thinking I might be able to change the whole bolt, if it is a bolt. This truck needs more love than I have time to give it, going back to New England to work tomorrow…wanted to get more accomplished but it is what it is. Going to order a new fuel filter bracket since I was able to get the two nuts completely off and back on. Didn’t swap filter cuz I have to study the Haynes to figure out how to relieve fuel pressure before I attempt to crack the lines. I did prep every rusty bolt I could spray today. The bed of the truck is coming off one way or another next time I’m home. It’s not going to be easy

    IMG_3102.jpg
    IMG_3103.jpg
    IMG_3104.jpg
    IMG_3105.jpg
    IMG_3106.jpg
    IMG_3107.jpg
     
  4. Sep 14, 2025 at 12:30 PM
    #24
    renots

    renots [OP] 15mpgTaco just entered the chat

    Joined:
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    Gender:
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    First Name:
    Doug
    Southern Illinois
    Vehicle:
    04 Tacoma SR5 TRD OR 3.4L M/T 4x4
    OME suspension lift 882 coil overs Aftermarket UCAs and upper ball joints with zerks Arb bumper with warn winch All new dakkar leaf springs Diff drop kit Suspension parts purchased at wheelers off road 32” all terrains and nicer bullet hole rims.
    I think when they replaced the frame they reused all the rusty bolts and nuts. Those toggle looking bolts for the body look bad. Also the pic I added of the rot hole in the bed is the front corner of the passenger side. That’s the only spot that has rotted clear through. I believe I need to tear the whole truck down and replace all these rusty bolts or it won’t be possible soonish, even if it’s still possible now. The more I work on it, the more I think maybe I should sell it but I don’t want to sell.
     
  5. Sep 14, 2025 at 1:21 PM
    #25
    renots

    renots [OP] 15mpgTaco just entered the chat

    Joined:
    Jun 29, 2014
    Member:
    #132951
    Messages:
    307
    Gender:
    Male
    First Name:
    Doug
    Southern Illinois
    Vehicle:
    04 Tacoma SR5 TRD OR 3.4L M/T 4x4
    OME suspension lift 882 coil overs Aftermarket UCAs and upper ball joints with zerks Arb bumper with warn winch All new dakkar leaf springs Diff drop kit Suspension parts purchased at wheelers off road 32” all terrains and nicer bullet hole rims.
    Reading the Haynes trying to figure out what those bolts with oval shaped brackets coming through the body near rocker panels holds on, and if they can be replaced. I am ready to stay the course and start renovating this thing one weekend at a time if you guys think it’s even possible and worthwhile. I desire to keep this thing.

    IMG_3104.jpg
     

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